Awning or patio cover mounting apparatus

ABSTRACT

Weather-resistant awning or patio cover attachment apparatus having a flexible flashing element and non-mastic wall and end seals for sealably mounting a rigid awning frame to a support wall.

United States Patent [191 Bamberger 51 Oct. 14, 1975 AWNING oR PATIOCOVER MOUNTING APPARATUS [75] Inventor:

[73] Assignee: Westerner Products, Inc., Tucson,

Ariz.

[22] Filed: July 22, 1974 [21] Appl. No.: 490,773

Larry F. Bamberger, Tucson, Ariz.

2,830,334 4/1958 Schroyer 52/76 2,834,072 5/1958 Miller 52/77 2,867,2731/1959 Brennan et a1. 49/71 X 3,092,171 6/1963 Deddo 52/78 X 3,286,40411/1966 Harrison 52/75 X 3,381,423 5/1968 Fe1d 52/78 3,413,769 12/1968Hoyt 52/287 X 3,429,070 2/ 1969 Hurst 52/74 X 3,447,273 6/1969 Thom52/403 X 3,869,837 3/1975 Dunn 52/75 Primary Examiner-Frank L. AbbottAssistant ExaminerLes1ie A. Braun [57] ABSTRACT Weather-resistant awningor patio cover attachment apparatus having a flexible flashing elementand nonmastic wall and end seals for sealably mounting a rigid awningframe to a support wall.

4 Claims, 5 Drawing Figures US. Patent Oct. 14, 1975 AWNING OR PATIOCOVER MOUNTING APPARATUS BACKGROUND OF THE INVENTION 1. Field of theInvention This invention relates to mounting apparatus for sealablysecuring a rigid awning or patio cover frame to a support wall withminimal use of mastic materials.

2. Description of the Prior Art Window and door awnings constructed ofvarious flexible materials have long been known. Rigid awningsfabricated from corrugated panels and the like are also well known andwidely used. The rigid awnings are generally constructed of a singlepanel or a series of interlocking panels fabricated from sheet aluminum,fiber glass or similar light weight rigid materials which are supportedin an awning frame that attaches to the exterior wall of a building or amobile home.

Two elements of support are usually used for attaching rigid awnings toa support wall. One of the elements is a wall bracket which attaches tothe support wall and to the awning frame. The other is a support columnor similar structure located at the exterior edge of the awning orawning frame and extending to the ground to provide support for thefront edge of the awning. Alternatively, support for the front edge ofthe awning may be in the form of truss elements which attach to thesupport wall and to the awning frame.

Unlike fabric awnings or rollup awnings, rigid awnings are often notintended to be retracted. As a result, the support element adjacent tothe support wall generally positions the awning frame in a singleangular position relative to the support wall. In such installations,the awning will typically be mounted to the support wall when it isinstalled and thereafter will not be moved.

However, in many instances it becomes desirable to allow the awningpanel to be pivoted somewhat relative to the support wall. Such is thecase, when in attaching the awning to a mobile home or other structureit is desired to choose one of several pitch angles so that proper waterrunoff is achieved. In addition, when the awning moves or flexes due towind or the weight of snow, the pivot prevents these movements frombeing transmitted to the wall bracket which could be loosened as aresult. As a result, various methods have been used in the past forpivotally mounting the awning to the support wall. One example of such amounting means is disclosed in U.S. Pat. No. 3,286,404 by J. K. Harrisonwhere the awning is intended to be swung all the way down to a verticalposition.

When pivotable attachment apparatus is used for attaching a rigid awningto a support wall, it is necessary that sealing means be provided tokeep water or snow from blowing past the apparatus onto the area beneaththe awning. Various methods have been utilized in attempting to providesealing means for such apparatus. The primary element presently utilizedfor sealing purposes is a mastic material such as caulking or puttycompound. Typically, such mastic material is applied between the hingeapparatus and the support wall to prevent the flow of water around themounting apparatus and down the support wall onto the area beneath theawning. In addition, it has been common for caulking material to beapplied along various joints of the mounting apparatus to preventleakage where metal parts interlock. This is particularly necessary in apivoted mounting where the metal parts must be free to move with respectto one another and where moisture may creep in between the moving partsand possibly freeze. It has also been common to use various flashingelements which act to cover portions of the hinge apparatus. Theflashing elements of which applicant is aware are sealed directlyagainst the support wall by the use of putty or caulking.

In each of these instances, where putty, caulking or other masticmaterial is used, serious problems have arisen. Because of the use ofawnings in various climate extremes, it is common for the caulkingmaterial to shrink or become brittle due to the effects of extreme cold,drying wind or sunlight. As a result, the caulking or putty will dry,become dislodged or otherwise allow the rain or snow to seep into thehinge apparatus and onto the area beneath the awning. In addition, theputty or caulking material is particularly troublesome in the case ofpivoted mounting apparatus where the parts must continually move withrespect to one another due to vibration and the like, causing thecaulking to break away, crack or loosen.

SUMMARY The present invention is an awning attachment apparatus forsealably mounting a rigid awning frame to a support wall with minimaluse of mastic materials. It provides an awning rail which can be securedto a support wall at any number of discrete locations. An awning hangeris pivotally secured to the rail such that an awning panel attached tothe hinged hanger can be positioned in any one of several angularpositions to provide for effective water runoff. A non-mastic spongeseal is provided between the awning hanger and the awning panel.

Cleat members attached to the awning hanger and a correspondingretention lip on the rail provide retaining recesses for a flexibleflashing element. These recesses allow the flashing element to besealably held in place when the awning panel is at any one of severalangular positions and effectively prevents rain and snow from seepingthrough the hinge apparatus. In addition, end-seals are provided for theends of the hinge apparatus to prevent moisture from entering. Anon-mastic sponge seal is inserted between the rail apparatus and thesupport wall to further prevent the flow of moisture to the shelteredarea beneath the awning.

The present weather resistant attachment apparatus allows a rigid awningto be pivotally attached to a building or mobile home. The awning panelcan be moved to any one of several positions without degrading thesealing ability provided by the hinge apparatus. The use of flexibleflashing elements, a non-mastic seal between the rail and the supportwall, and resilient end seals helps prevent the flow of moisture pastthe hinge apparatus or its accumulation within the hinge apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of arigid awning mounted to a support wall by the weather resistantattachment apparatus;

FIG. 2 is a side elevational view of the weather resistant attachmentapparatus;

FIG. 3 is a partially cut away sectional view along the line 33 in FIG.2;

FIG. 4 is a side elevational view of an alternative embodiment of theweather resistant attachment apparatus; and

FIG. 5 is a perspective view of an end-seal for use with the weatherresistant attachment apparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1-5, whereinlike numerals refer to like structural elements, the awning attachmentapparatus 1 is a sealed means for pivotally mounting a rigid awningpanel 16 to a support wall 30. The attachment apparatus 1 is comprisedof a mounting rail 20 which is attached to support wall 30 and whichpivotally supports awning hanger to which is attached the rigid awningpanel 16.

Referring to FIGS. 1 and 2, it is seen that the awning panel 16 is acorrugated panel which can be a single panel or a plurality of discretesegments which are joined together to form a shelter for the area belowthe awning. The awning panel 16 is carried in an awning frame 18 whichis generally a rectangular structure having an eave spout (not shown)for carrying off the water which runs off of the panel 16. Inalternative embodiments (not shown) the awning hanger may or may not bean integral part of the awning frame.

As is shown in FIG. 2, awning panel 16 is attached to awning hanger 10by means of screws 16a and 16b. Other suitable means of attachment mayalso be used. In the preferred embodiment, hanger 10 forms an integralpart of awning frame 18. A water resistant sponge seal 17 is insertedbetween the awning panel 16 and awning hanger 10. This flexible materialprovides a seal between the panel 16 and hanger 10 which prevents rainor snow from passing through the awning at this assembly joint. Seal 17may be a sponge-tape or similar flexible, non-mastic material which isresistant to cracking or leaking caused by temperature changes orvibration of the awning. In the preferred embodiment, seal 17 haspre-applied adhesive on the side abutting awning hanger 10. Awninghanger 10 consists of an extension element 12 which is joined to avertical element 11 which in turn joins a support element 15. One end ofextension element 12 terminates in the rounded hinge bar 14 whosefunction will be described in detail later and which is one of twopivoting elements which form the hinge for attachment apparatus 1.

Awning hanger 10 is utilized to mount the awning panel 16 to supportwall 30 by means ofa mounting rail 20. As is seen in FIG. 2, mountingrail 20 is comprised of a generally flat mounting plate 21 havingretention lips 22 and 22a at its upper end and a tubular enclosureelement 23 at its lower end. Enclosure element 23 has a hinge opening 24which is intended to interlock with the hinge bar 14 to form a pivotpoint between awning hanger 10 and mounting rail 20. The purpose ofretention lips 22 and 22a will be described in detail later.

In the embodiment shown in FIGS. 1 and 2, hinge bar 14 and hingeenclosure element 23 both extend the length of the awning panel 16 toprovide continuous support for panel 16 on support wall 30. However, inalternative embodiments (not shown) these elements may be of variouslengths without impairing their ability to support one another and forma hinge.

An end-seal 26 is placed in hinge opening 24 to prevent the flow ofmoisture into the hinge from the ends of enclosure element 23. In theembodiment shown,

end-seal 26 consists of a resilient tape which adheres to the end ofenclosure element 23. A properly contoured plastic plug (not shown) or apliable putty element (not shown) may also be used for end-seal 26.

Mounting rail 20 is attached to support wall 30 by means of fasteningscrews 25. In the preferred embodiment, rail 20 is a continuous elementwhich extends the length of the awning panel. Because of the width andbreadth of mounting rail 20, screw holes can be inserted in it at anynumber of discrete locations. This provides versatility for theinstallation of the awning attachment apparatus 1 in that mounting screwholes can be located at any point where there is a structural memberwithin the support wall 30. Means other than screws 25 may also be usedwhere appropriate. The unitary nature of rail 20 reduces the chance forleaking and the need for sealing.

In the preferred embodiment shown in FIG. 2, a nonmastic water resilientsealing element 31 is inserted between mounting rail 20 and the supportwall 30. Sealing element 31 can be fabricated of any one of severalnonmastic materials which are water resistant and pliable, but which donot crack or loosen due to vibration or extreme climate. Because sealingelement 31 is pliable, when the mounting rail 20 is tightened againstsupport wall 30 the soft material of sealing element 31 tends to fillany voids which would exist at the interface between the two elements.This prevents the passage of moisture along the support wall to the areabeneath the awning. Such sealing capability is particularly valuablewhen the support wall has a grooved or textured surface as withrough-hewn siding, stucco or brick. Sealing element 31 would typicallyextend the entire length of mounting rail 20 to provide a good watertight seal between the mounting rail 20 and the support wall 30.

The use of water resistant sealing element 31 would normally eliminatethe need for caulking between mounting rail 20 and support wall 30.However, caulking may still be used in certain instances for additionalprotection, but it is usually unnecessary and undesirable in that ittends to crack and deteriorate in extreme climates and as a result ofvibration or flexing of the awning attachment apparatus 1.

To prevent rain or snow from penetrating between the two hinge element23 and 14, a flexible flashing element 19 is provided. This is shown inFIG. 2 and in an alternative installation embodiment in FIG. 4, whichwill be described in detail later. Flexible flashing element 19 isfabricated from a thin flexible material such as steel, aluminum orplastic and is held in place between mounting rail 20 and hangerextension element 12 by means of a retention lip 22 and any one of theplurality of cleat members, each designated by the numeral 13.Rentention lip 22 is a part of mounting rail 20 and extends generallyoutwardly and downwardly from mounting plate 21 to form a grooved recessalong the length of mounting rail 20. cleat members 13 are protuberancesextending up from extension element 12 and are angled in a directiontoward the support wall. Cleat members 13 provide an angled recess alongthe length of extension element 12.

Flashing element 19 is held in place by inserting its upper edge 19aunder either retention lip 22 or 22a and its bottom edge 19b under oneof cleat members 13. Flashing element 19 is bent when inserted beneaththe retention elements and the internal stresses which the bendingproduces help retain it in place once it is inserted. In the embodimentshown in FIG. 2, flexible flashing element 19 is flexed such that it isconvex outward. Because of the stress imparted to flexible flashingelement 19 when it is inserted in place a generally tight seal isestablished between it and retention lip 22 and cleat member 13. Thisabutting engagement, in addition to the overhanging effect of retentionlips 22 and 22a and cleat member 13, helps preventrain or snow frommigrating past flashing element 19 into the hinge apparatus. As aresult, an effective weather seal is established.

Three separate cleat members 13 are shown in FIG. 2. While only onecleat is utilized to hold flashing element 19 in place, severaldifferent cleat locations provide several different locking positionsfor flashing element 19. Thus, a particular cleat location may beselected when the awning is moved into any one of several angledorientations with respect to support wall 30. Similarly, a second lipextension 22a is provided on rail member 20. Either lip 22 or 22a may beutilized to properly retain flashing element 19. More retention lips(not shown) may also be utilized. As a result, a single awning hanger land a single rail 20 is provided which accommodates awnings which arepositioned at various angular orientations with respect to the supportwall 30.

During the installation of the awning 16 on support wall 30 a cleatmember 13 is selected which provides the best sealed insertion forflexible flashing element 19. As a result, it is not necessary thatvarious awning hanger designs or various sizes of flashing element 19 beprovided. The embodiment shown in Flg. 4 shows flashing element 19inserted beneath retention lip 22 and cleat member 13 such that it isconcave outward, i.e. when viewed from above the awning.

To prevent the passage of rain into the ends of the attachment apparatus1, a sponge material end-seal 27 covers the end opening formed betweenflashing element 19, extension element 12 and mounting plate 21. In apreferred embodiment, end-seal 27 is a sponge-like resilient materialwhich can be easily inserted during installation of the awning and canbe deformed to take the particular shape of the opening into which it isinserted. This flexibility allows one-sized end-seal 27 to be usedregardless of which cleat member 13 is used for retaining flashingelement 19.

In installations where it is desired that a more rigid end-seal beutilized to protect the opening between flashing element 19 andextension element 12, an alternative end plug 27a (see FIG. 5) may beutilized. End 27a ais comprised of an insert portion 29 which iscontoured to exactly fit the opening between the various elements of theattachment apparatus 1. Attached to element 29 is an exterior plate 28which extends across the outside ends of the hinge elements to providean attractive covering device. When an end-seal such as 27a is desired,various sizes of insert portion 29 may be provided to fit into theattachment apparatus 1 when flashing element 19 is in any one of theseveral cleat members l3.

The installation and use of the awning hinge apparatus 1 can besummarized as follows. The awning mounting rail 20 is attached to asupport wall 30 by means of screws 25 or other fastening devices (notshown). Water resilient non-mastic sealing element 31 is positionedbetween mounting rail 20 and support wall 30 before it is tightenedagainst the support wall. This prevents the flow of moisture between thesupport wall 30 and rail 20. Because mounting rail 20 extends the lengthof the awning panel 16, any number of anchoring positions may be chosenon it for securing it to reinforced portions of support wall 30.

Awning hanger 10 is attached to mounting rail 20 by tilting hanger 10upwardly and inserting the leading edge 14a of hinge bar 14 into hingeopening 24. When awning hanger 10 is pivoted downward to the desiredinstallation angle, hinge bar 14 automatically locks into positionwithin hinge opening 24. Attachment may also be accomplished by slidinghinge bar 14 into hinge opening 24 on mounting rail 20. The generallycylindrical interface between hinge enclosure element 23 and hinge bar14 provides a pivot for the attachment apparatus 1. After the awningpanel 16 or the frame 18 upon which it is mounted is located in thedesired angular position relative to support wall 30, flexible flashingelement 19 is inserted by flexing it such that its ends are insertedbeneath a retention lip (22 or 22a) and a cleat member 13. When the flexis released on the flashing element 19, enough tension remains in it toprovide a tight engagement between it, retention lip 22 or 22a and thecleat member 13.

To shield the ends of attachment apparatus 1 from rain and snow end-seal26 is inserted in hinge opening 24 and end-seal 27 is inserted betweenflashing element 19 and extension element 12. End-seal 27 can be eithera pliable sponge-like material which can be formed to completely enclosethe opening beneath flashing element 19 or it can be a semi-rigidelement 27a which is specially contoured to fit into the opening beneathflashing element 19. With these various elements in place, awning panel16 or awning frame 18 is securely attached to support wall 30 in aweather-resistant manner without need for extensive use of masticsealants such as caulking or putty.

Channel 15a extends the width of awning panel 16. It is intended as achannel to receive a snap-in splice bar (not shown) which would beinserted to hold two adjoining panel units in alignment. In addition,screw channel 15b extends the width of hanger 10 to allow the sectionsof panel 16 to be anchored in place at any location by means of screws16b.

What is claimed is:

1. Awning or patio cover attachment apparatus for sealably mounting arigid awning panel to a support wall with minimal need for caulking,comprising:

a. a unitary.awning rail member attachable to the support wall;

b. an awning hanger for supporting the awning panel, said hangerattached to the edge of the awning panel which is adjacent the supportwall;

c. hinge means for pivotally attaching said hanger to said rail member;

d. shielding means to prevent the passage of rain through said hingemeans, said shielding means including:

i. a flexible flashing element having first and second opposed edges,said flashing element extending between said rail member and saidhanger;

ii. at least one retention lip attached to said rail member and forminga recess for retaining the first edge of said flashing element ingenerally sealed mechanical engagement therewith; and

iii. at least one cleat member attached to said awning hanger andforming a recess for retaining the second edge of said flashing elementin general-1y sealed mechanical engagement therewith;

e. non-mastic means for attaching said flashing element to said railmember and said awning hanger in a generally sealed relationship theretowhen the awning frame is positioned in any one of several pitchorientations; and

f. a flexible, non-mastic water resistant sealing element sealablyattached to said rail member and abuttable against the support wall,said sealing element being compressible to conform to the contour of thesupport wall thereby preventing the flow of moisture therebetween.

2. The attachment apparatus of claim 1 wherein said flashing element isformed from a resilient material which can be flexed to produce stresstherein, said flashing element opposed edges insertable beneath saidretention lip and said cleat member in a flexed mode to be retainedtherebetween by the elastic stresses in the flashing element.

3. The attachment apparatus of claim 1 wherein there are provided aplurality of retention lips attached to said rail member in a generallyvertical array and wherein there are a plurality of cleat membersattached to said awning hanger in a generally vertical array, saidretention lips and said cleat members serving to retain said flashingelement in sealed relationship when the awning frame is positioned inany one of several pitch orientations.

4. Awning or patio cover attachment apparatus for sealably mounting arigid awning panel to a support wall with minimal need for caulking,comprising:

a. a unitary awning rail member attachable to the support wall;

b. a flexible, non-mastic water resistant sealing element sealablyattached to said rail member and abuttable against the support wall,said sealing element being compressible to conform to the contour of thesupport wall thereby preventing the flow of moisture therebetween;

c. an awning hanger for supporting the awning panel, said hangerattached to the edge of the awning panel which is adjacent the supportwall;

d. hinge means for pivotally attaching said hanger to said rail member;

e. shielding means to prevent the passage of rain through said hingemeans, said shielding means in cluding a flexible flashing elementhaving first and second opposed edges, said flashing element extendingbetween said rail member and said hanger;

f. non-mastic means for attaching said flashing element to said railmember andsaid awning hanger in a generally sealed relationship theretowhen the awning frame is positioned in any one of several pitchorientations;

g. a first water resistant end-seal insertable in the end opening formedby said flashing element, rail member and awning hanger near the end ofsaid flashing element to prevent the passage of moisture therein; and

h. a second water resistant end-seal attachable to the end of said hingemeans to prevent the passage of moisture into said hinge means, saidsecond endseal being a pliable water resistant element having adhesiveon one side for abuttable sealed engagement with the end of said hingemeans.

1. Awning or patio cover attachment apparatus for sealably mounting arigid awning panel to a support wall with minimal need for caulking,comprising: a. a unitary awning rail member attachable to the supportwall; b. an awning hanger for supporting the awning panel, said hangerattached to the edge of the awning panel which is adjacent the supportwall; c. hinge means for pivotally attaching said hanger to said railmember; d. shielding means to prevent the passage of rain through saidhinge means, said shielding means including: i. a flexible flashingelement having first and second opposed edges, said flashing elementextending between said rail member and said hanger; ii. at least oneretention lip attached to said rail member and forming a recess forretaining the first edge of said flashing element in generally sealedmechanical engagement therewith; and iii. at least one cleat memberattached to said awning hanger and forming a recess for retaining thesecond edge of said flashing element in generally sealed mechanicalengagement therewith; e. non-mastic means for attaching said flashingelement to said rail member and said awning hanger in a generally sealedrelationship thereto when the awning frame is positioned in any one ofseveral pitch orientations; and f. a flexible, non-mastic waterresistant sealing element sealably attached to said rail member andabuttable against the support wall, said sealing element beingcompressible to conform to the contour of the support wall therebypreventing the flow of moisture therebetween.
 2. The attachmentapparatus of claim 1 wherein said flashing element is formed from aresilient material which can be flexed to produce stress therein, saidflashing element opposed edges insertable beneath said retention lip andsaid cleat member in a flexed mode to be retained therebetween by theelastic stresses in the flashing element.
 3. The attachment apparatus ofclaim 1 wherein there are provided a plurality of retention lipsattached to said rail member in a generally vertical array and whereinthere are a plurality of cleat members attached to said awning hanger ina generally vertical array, said retention lips and said cleat membersserving to retain said flashing element in sealed relationship when theawning frame is positioned in any one of several pitch orientations. 4.Awning or patio cover attachment apparatus for sealably mounting a rigidawning panel to a support wall with minimal need for caulking,comprising: a. a unitary awning rail member attachable to the supportwall; b. a flexible, non-mastic water resistant sealing element sealablyattached to said rail member and abuttable against the support wall,said sealing element being compressible to conform to the contour of thesupport wall thereby preventing the flow of moisture therebetween; c. anawning hanger for supporting the awning panel, said hanger attached tothe edge of the awning panel which is adjacent the support wall; d.hinge means for pivotally attaching said hanger to said rail member; e.shielding means to prevent the passage of rain through said hinge means,said shielding means including a flexible flashing element having firstand second opposed edges, said flashing element extending between saidrail member and said hanger; f. non-mastic means for attaching saidflashing element to said rail member and said awning hanger in agenerally sealed relationship thereto when the awning frame ispositioned in any one of several pitch orientations; g. a first waterresistant end-seal insertable in thE end opening formed by said flashingelement, rail member and awning hanger near the end of said flashingelement to prevent the passage of moisture therein; and h. a secondwater resistant end-seal attachable to the end of said hinge means toprevent the passage of moisture into said hinge means, said secondendseal being a pliable water resistant element having adhesive on oneside for abuttable sealed engagement with the end of said hinge means.